Apparatus and method for manufacturing thin film electrode of hydrous ruthenium oxide

ABSTRACT

An apparatus and a method are provided for manufacturing an electrode of hydrous ruthenium oxide thin film. The apparatus comprises an injector for introducing a precursor solution and spraying the precursor solution; a substrate having the precursor solution sprayed thereon; a substrate-supporting base for supporting the substrate and including a halogen lamp therein for heating the substrate; a direct current power supply connected to the substrate-supporting base and the injector; a distance adjuster for adjusting the distance between the substrate-supporting base and the injector; and a temperature controller for controlling the substrate-supporting base. Under a strong electric field, the ruthenium precursor solution is sprayed, to yield a porous thin film electrode having very fine particles. The electrode prepared by the method which is advantageous in terms of simplified preparation process and shorter period of time required for preparation, compared to conventional methods, has more excellent properties than those of a conventional ruthenium oxide electrode for super capacitor or a composite electrode of ruthenium oxide and activated carbon.

TECHNICAL FIELD

[0001] The present invention relates to an apparatus and a method for preparing a thin film electrode of hydrous ruthenium oxide. More specifically, the present invention relates to an apparatus and a method for preparing an electrode of hydrous ruthenium oxide thin film by spraying ruthenium precursor solution on a heated substrate under strong electric field, thus forming a porous thin film electrode of very fine size.

PRIOR ART

[0002] Generally, a high performance portable power supply has been used as a main component of end-products essentially used in all portable information communication equipment, electronic apparatus, electric automobile and so on. Next generation energy storage systems, which are recently developed, utilize electrochemical principles and are exemplified by a Li based secondary cell and an electrochemical capacitor.

[0003] In this regard, the secondary cell is advantageous in terms of energy amount (energy density) that it is capable of accumulating per unit weight or unit volume, but is disadvantageous in light of energy amount (power density), applicable per time, period of use, and charging time. Meanwhile, the electrochemical capacitor has energy density smaller than the secondary cell, but is more advantageous in terms of duration of use, charging time and power density, compared to the secondary cell. So, in the case of electrochemical capacitor, research for improving energy density has been vigorously performed. The electrochemical capacitor with ultrahigh capacitance by use of electrochemical principles is classified into an electrical double layer capacitor (EDLC) using a principle of electrical double layer, and a supercapacitor showing ultrahigh capacitance which has maximal capacitance 10 fold larger than that of EDLC by pseudocapacitance generated from electrochemical faradaic reaction. In the case of the EDLC, activated carbon/fiber is useful as electrode material of the capacitor, and thus an electric charge of high density is accumulated in the electrical double layer. As the electrode material in the supercapacitor, use can be made of metal oxides.

[0004] Such a supercapacitor having high capacitance and high power density can be used alone or in combination with a secondary cell in the fields of power supplies for electromobile, portable mobile communication equipment, memory back-up of computer, military and aeronautic apparatus, and micro medical equipment. EDLC using synthetic carbon material as electrode has been commercially available from the early 1980s in Japan, thus its practical development reaching its technical limits. Regular research for metal oxide based electrode material-using supercapacitor has been carried out for only the past 4-5 years in the Unites States and Japan. However, supercapacitors suffer from the drawbacks of expensive electrode active materials and difficult preparation process, and thus are used as only for special purposes, such as military affairs. Its commercial use is delayed.

[0005] On the other hand, the electrode materials for supercapacitor developed until now comprise RuO₂, IrO₂, NiO, CoOx, MnO₂, WO₃ and the like. Of these materials, RuO₂ and IrO₂ show the most excellent electrochemical properties, while the other materials have poor properties. Most research places emphasis on these two materials. In particular, ruthenium oxide with very excellent performance has been widely studied as metal oxide electrode for supercapacitor applications.

[0006] In general, ruthenium oxide is largely divided into anhydrous type and hydrous type.

[0007] As a method for manufacturing an electrode of ruthenium oxide for supercapacitor, an anhydrous ruthenium oxide electrode and a hydrous ruthenium oxide electrode are prepared by pyrolysis and sol-gel processes, respectively. As for pyrolysis process, RuCl₃.xH₂O dissolved in distilled water or alcohol is used as a precursor solution and pyrolyzed on a conductive metal substrate at high temperature 350-500° C. As such, tantalum or titanium is used as substrate material, and, in particular, titanium is preferred because of excellent adhesion between titanium and RuO₂. In the case of sol-gel process, a precursor solution is RuCl₃.xH₂O in distilled water, like the pyrolysis process, to which aqueous NaOH solution is slowly added to maintain pH of the solution at about 7. Ru(OH)₃ is thermodynamically stabilized and precipitated in the solution in black powder form. The precipitated ruthenium powder is filtered with about 8 μm-caliber filter and then washed. The washing is performed by repeating 5 times the procedure in which distilled water is poured to a powder-containing vessel to a suitable volume, stirred for 30 minutes, and filtered. Thusly obtained final product is RuO₂.2H₂O, which is then thermally treated at appropriate temperature for 17 hours, thereby yielding hydrous ruthenium oxide powder. In order to employ the powder as a practical electrode, the powder is mixed with Teflon binder in a mass ratio of 5% and rolled, to prepare an electrode in a thin film form of 100-200 μm. Such electrode of hydrous ruthenium oxide has high capacitance of 720 F/g, but suffers from the disadvantages of poor discharge/charge properties and low power properties. To alleviate these disadvantages, powders prepared by sol-gel process are mechanically mixed with about 20% activated carbon and then Teflon binder, to yield a composite electrode, which has specific capacitance of 650 F/g lower than that of hydrous ruthenium oxide electrode, at slow discharge rate, but maintaining a specific capacitance of about 600 F/g at fast discharge rate. However, sol-gel process is disadvantageous in light of very complicated multiple preparation steps and long periods of time required for preparation.

DISCLOSURE OF THE INVENTION

[0008] With the problems encountered in the prior arts in mind, the present invention has an object of providing a method for manufacturing a thin film electrode of hydrous ruthenium oxide having more excellent performance through a simplified EASP (electrostatic aerosol spray pyrolysis) process requiring short period of time, compared to a complicated sol-gel process requiring long periods of time.

[0009] It is another object of the present invention to provide an apparatus for manufacturing a thin film electrode of hydrous ruthenium oxide.

[0010] In accordance with an embodiment of the present invention, there is provided an apparatus for manufacturing a thin film electrode of hydrous ruthenium oxide, comprising: a scanner, for introducing a precursor solution and spraying said precursor solution; a substrate, for having said precursor solution sprayed thereon; a substrate-supporting base, for supporting said substrate and including a halogen lamp therein for heating said substrate; a direct current power supply, connected to said substrate-supporting base and said scanner; a distance adjuster, for adjusting the distance between said substrate-supporting base and said scanner; and a temperature controller, for controlling said substrate-supporting base, in which said scanner comprises an electronic flow regulator for accurately controlling a spraying amount by regulating a pushing speed of a piston within the scanner, said distance adjuster maintaining the distance between the scanner and the substrate-supporting base at a length of 0.5-10 cm, and said temperature controller evaporating solvent in said precursor solution, and maintaining pyrolyzable temperature of said precursor solution, thus forming an oxide or a oxide precursor.

[0011] In accordance with another embodiment of the present invention, there is provided a method for manufacturing a thin film electrode of ruthenium oxide, comprising the following steps of: preparing a precursor solution, RuCl₃.xH₂O in ethanol; introducing said precursor solution into a scanner; heating a substrate by use of a halogen lamp; connecting a substrate-supporting base and said scanner through a direct current power supply; spraying said precursor solution on said heated substrate; and thermally treating an electrode deposited on said substrate.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0013]FIG. 1 is a schematic block diagram showing an EASP apparatus according to the present invention.

[0014]FIGS. 2a to 2 c are voltamograms showing electrochemical properties of a thin film electrode of hydrous ruthenium oxide according to the present invention, obtained by cyclic voltammetry at scan rate of 2 mV/sec in 0.5 M H₂SO₄ solution (a), at scan rate of 20 mV/sec in 0.5 M H₂SO₄ solution (b), and at scan rate of 50 mV/sec in 0.5 M H₂SO₄ solution (c).

[0015]FIGS. 3a and 3 b are microphotographs taken by a scanning electron microscope (SEM) for observing surface shape of the electrode at 5000 and 30000 magnifications, respectively.

BEST MODES FOR CARRYING OUT THE INVENTION

[0016] With reference to FIG. 1, there is shown an electronic aerosol spray pyrolysis (EASP) apparatus used in the present invention. As can be seen in this figure, an electronic flow regulator 1, capable of regulating a speed of a piston to be pushed for accurately controlling a spraying amount, is attached to a scanner 2. A needle of the scanner is electrically connected to a stainless steel substrate-supporting base 4 through a high-voltage direct current power supply 7 located therebetween, to form a strong electric field between the scanner 2 and the supporting base 4. A halogen lamp 6 is mounted within the supporting base 4. For constantly maintaining the temperature of the supporting base 4 which is heated by the lighting halogen lamp 6, a temperature controller 5 is connected to the lamp 6.

[0017] In particular, the halogen lamp 6, an exothermic body, is designed to allow the stainless steel substrate-supporting base to be miniaturized. When the supporting base is heated by such lamp, heat transfer to the upper parts is minimized and thus aerosol spray can be stably formed by strong electric field.

[0018] The scanner 2, which is connected to the electronic flow regulator 1, can control the flow of the solution sprayed from this scanner 2 within an error range of 0.01 ml/h.

[0019] A distance adjuster 8 can maintain the distance between the scanner 2 and the supporting base 4 at a length of 0.5-10 cm.

[0020] The temperature controller 5 can evaporate solvent in a precursor solution, and also maintain pyrolyzable temperature of the precursor solution.

[0021]FIGS. 2a to 2 c show graphs illustrating electrochemical properties of the thin film electrode of hydrous ruthenium oxide according to the present invention. These graphs have characteristics of hysterisis curves, in which the electrode charges a predetermined capacitance and then discharges until all predetermined capacitance is consumed with maintaining constant current. In this regard, when the voltage is increased from 0 to 1000 mV, the current is maintained at 3 mA. On the other hand, when the voltage is decreased from 1000 to 0 mV, the current is maintained at −3 mA. An angulation in current and voltage relationship, which maintains a constant current according to constant change of voltage, is a unique electrochemical property of theoretical electrochemical capacitor. FIGS. 2a to 2 c illustrate the relationships of current and potential when scan rates are 2 mV/sec, 20 mV/sec and 50 mV/sec.

[0022] Turning now to FIGS. 3a and 3 b, there are shown microphotographs of 5000 and 30000 magnifications, respectively, measured by use of a SEM, for observing surface shape of the electrode.

[0023] In order to measure electrochemical properties of the thin film electrode of hydrous ruthenium oxide according to the present invention, cyclic voltammetry (CV) is carried out in 10 cycles or more, using 0.5 M H₂SO₄ solution at scan rates of 2 mV/sec, 20 mV/sec and 50 mV/sec. The surface shapes of the same test pieces were observed by a SEM at 5000 and 30000 magnifications. As the CV observation results, when the scan rate is 20 mV/sec, a level of specific capacitance is found to be 650 F/g. Even though the scan rate is increased to 50 mV/sec or higher, the specific capacitance is maintained similarly to the cases of 2 mV/sec and 20 mV/sec, in the level of high specific capacitance. The results of CV also show the property of the capacitor illustrating angulation. Additionally, as the SEM measurement result, it can be seen that the surface of the electrode is composed of a porous structure comprising very fine particles of nanometer sizes.

[0024] In a preferred example of the present invention, a method for manufacturing a thin film electrode of hydrous ruthenium oxide through the EASP process largely comprises the following 5 steps.

[0025] In preparing a precursor solution as a first step, the precursor solution useful in EASP process is RuCl₃.xH₂O in ethanol, in which a heterogeneous solvent may be mixed with ethanol. By mixing a heterogeneous solvent, boiling points of the solution which are directly related to surface shape of the electrode can be increased or decreased. So, the thin film electrode having three-dimensional porous structure can be fabricated. As such, concentration of the solution ranges 0.001 M to 0.5 M.

[0026] In providing a substrate as a second step, electrode substrate usable in the EASP process uses Pt foil and Pt-deposited silicon wafer, including titanium and tantalum. Pt-deposited silicon wafer is prepared by thinly depositing TiO₂ oxidized at high temperature on silicon wafer to improve adhesion between Pt and silicon wafer, depositing Pt thereon, and washing the surface of the substrate with acetone and then ethanol, to prepare an electrode by the EASP process. The precursor solution is pyrolyzed on the substrate to form ruthenium oxide. So, the substrate-placed supporting base is heated, thereby maintaining the necessary temperature. Additionally, the temperature of the supporting base is controlled by lighting the halogen lamp mounted therein. For practical EASP process, the temperature is maintained at 50-400° C., which is relatively lower than that of the pyrolysis process.

[0027] In forming stable spray as a third step, the high-voltage direct current power supply is connected between the substrate and the scanner, thus forming a strong electric field.

[0028] In spraying a precursor solution as a fourth step, the prepared precursor solution is sprayed by use of the scanner connected to the flow regulator. The precursor solution is introduced into the scanner, and the piston within the scanner is pushed at suitable flow velocity capable of spraying the solution, thereby beginning the spraying of the solution. A practical flow velocity ranges from 0.1 to 10 ml/h. As such, because the needle of the scanner is electrically connected to the stainless steel substrate-supporting base, when a strong electric field of 2 kV or higher is applied to the high-voltage direct current power supply, a tip of the needle is electrified to become a positive pole (+), and the substrate to become a negative pole (−). The precursor solution is electrified to (+) in the needle of the scanner, and thus converted into aerosol caused by inequality of surface tension and electrical repulsive force. Thusly formed aerosol is strongly affected by repulsive force of the same (+) pole, and hence instantly sprayed in a very fine droplet form. Simultaneously, strong attractive force corresponding to 2 kV or higher affects the substrate electrified as (−) pole, so spraying the aerosol at a fast rate to the substrate. Meanwhile, when the aerosol attracted by strong attractive force reaches the substrate maintained at boiling points or higher of ethanol, ethanol is evaporated and very fine particles of nano sizes are deposited on the substrate and pyrolyzed at the same time, to form a porous RuO₂.xH₂O thin film.

[0029] In thermally treating the electrode as a fifth step, the deposited electrode after completion of the spraying functions as an original RuO₂.xH₂O thin film electrode by a thermally activated procedure. This is referred to as a thermal treatment process, which is essentially required for all electrodes of metal oxides. In the case of ruthenium oxide electrode manufactured by EASP process, a desired electrode is obtained by thermal treatment which is carried out at about 100-600° C. for about 2-24 hours under gas atmosphere including oxygen.

[0030] In the manufacture of hydrous ruthenium oxide electrode using the EASP apparatus, the aerosol is sprayed to the substrate not by gravity but by attractive force of the applied electric field. Hence, EASP apparatus can be positioned horizontally or perpendicularly, or at optional gradient, versus the apparatus-placed surface.

INDUSTRIAL APPLICABILITY

[0031] The electrode of ruthenium oxide thin film for supercapacitor by the EASP process according to the present invention has high specific capacitance at fast scan rates in CV measurement for assaying capacitance of the electrode. In addition, the present electrode shows the angulation to be presented when a relationship of current and voltage in a capacitor is ideal, so that a supercapacitor maintaining high specific capacitance upon practical fast discharge/charge can be fabricated.

[0032] The present invention has been described in an illustrative manner, and it is to be understood that the terminology used is intended to be in the nature of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, it is to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. 

1. An apparatus for manufacturing a thin film electrode of hydrous ruthenium oxide, comprising: a scanner, for introducing a precursor solution and spraying said precursor solution; a substrate, for having said precursor solution sprayed thereon; a substrate-supporting base, for supporting said substrate and including a halogen lamp therein for heating said substrate; a direct current power supply, connected to said substrate-supporting base and said scanner; a distance adjuster, for adjusting the distance between said substrate-supporting base and said scanner; and a temperature controller, for controlling said substrate-supporting base.
 2. The apparatus as defined in claim 1, wherein said scanner comprises an electronic flow regulator for accurately controlling a spraying amount by regulating a pushing speed of a piston within the scanner.
 3. The apparatus as defined in claim 1, wherein said temperature controller evaporates solvent in said precursor solution, and maintains pyrolyzable temperature of said precursor solution.
 4. The apparatus as defined in claim 1, wherein said distance adjuster maintains the distance between the scanner and the substrate-supporting base at a length of 0.5-10 cm.
 5. The apparatus as defined in claim 1, wherein said precursor solution is RuCl₃.xH₂O in ethanol.
 6. The apparatus as defined in claim 5, wherein said ethanol solvent further comprises a heterogeneous solvent having an effect of increasing or decreasing boiling points of said precursor solution.
 7. A method for manufacturing a thin film electrode of ruthenium oxide, comprising the following steps of: preparing a precursor solution, RuCl₃.xH₂O in ethanol; introducing said precursor solution into a scanner; heating a substrate by use of a halogen lamp; connecting a substrate-supporting base and said scanner through a direct current power supply; spraying said precursor solution on said heated substrate; and thermally treating an electrode deposited on said substrate.
 8. The method as defined in claim 7, wherein said ethanol solvent further comprises a heterogeneous solvent having an effect of increasing or decreasing boiling points of said precursor solution, to prepare a very fine porous thin film electrode having three-dimensional regularity. 